Static deflection of cantilever thin wall workpieces in peripheral milling: An analytical model

Machining thin-walled components is a challenging task due to workpiece deflections and vibrations compromising process accuracy and productivity. To overcome these limitations, numerical models could be exploited to accurately predict workpiece behavior. Such models are generally complex and time-consuming, thus not easy to implement in optimization strategies or in the process planning stage. In this context, simplified analytical approaches could be useful, but the few methods available have limited impact. This paper presents an analytical and simplified method to estimate workpiece static deflection in thin wall milling, covering different types of plate geometries in the cantilever configuration. The proposed approach provides dedicated equations for thin plates according to their height to width ratio (i.e., width ratio), including cutting parameters, tool-workpiece material properties and workpiece geometry. The method has been numerically and experimentally validated. Finally, the proposed formulations were applied to analyze the most common cutting strategies in thin-wall milling and develop design diagrams which provide the most suitable cutting strategy according to the tool diameter, plate thickness, allowance available and radial depth of cut are presented. These diagrams are meant to be useful guidelines for the machinist dealing with thin-wall milling. • Analytical formulations to estimate workpiece deflection in thin-wall peripheral milling were developed • Proposed approach includes the impact of tool geometry, cutting parameters, workpiece geometry and material property • Experimental validation and comparison with already known state of the art approach was performed • Results showed that proposed formulations are a valid tool to estimate workpiece static deflection • Proposed approach was used to create diagrams to support machinist in selecting cutting parameters and cutting strategy